Building construction



`Oct. 15, 1940. F. GuNNIsoN i BUILDING CONSTRUCTION 3 sheets-sheet 2 Filed Aug. 50, 1958 INVENTOR F05 T57? GU/VN/JO/V AT1-ORNE@ 5 Sheets-Sheet 3 INVENTOR F O5 TE l? GUN/V/.SO/V

F. GUNNSON BUILDING CONSTRUCTION Filed Aug. 30, 1938 ATTORNEYS l Oct. 15, 1940.

Patented Oct. l5, 1940 UNITED STATES PATENT OFFICE 2,218,465 ummNc coNsrnuc'rroN Application August 30, 1938, Serial No.227,470

7 Claims.

This invention relates to prefabricated buildings, and more particularly to prefabricated houses suitable for permanent residential purposes and of such design and construction that -houses of various sizes and a plurality of floor plans may be readily constructed from standard interchangeable parts.

The invention also contemplates prefabricated houses which are adapted to various external and internal decorations either at the time of con- ".struction or subsequently, and adapted to subsequent rearrangement or enlargement of their floor plans by using the same standard parts or to the complete disassembly and reconstruction in a different location.

Prefabricated houses, as known heretofore, have been of several types, each type being subject to many serious disadvantages. In the socalledl ready-cut houses, the lumber and structural members of the house are out to the proper size in a factory andgafter numbering each of these members, these elements of the house are delivered to the site upon which the house is to'be built. The structural members are then nailed together and the lumber applied thereto in the usual manner of the conventionally built house. The only advantage in such a construction is that some saving is effected through the mass purchasing power of the seller of the structural members, together with a certain economy of labor in cutting the various structural members to the desired size.

The portable or ready-built type of house is that which comprises a conventional type of house wherein the members are made in large sections in a factory and then delivered to the site upon which the house is to be built. The final product resembles the conventional house in substantially all respects and is subject to the same disadvantages as the contruction of the conventional house. Among the most salient disadvantages in such a construction are the inflexibility and the permanence and finality of the structure. Once the building is nailed together, subsequent additions may not b e made without tearing down a portion of the house, such an operation requiring a considerable amount of labor and time and involving needless waste and expense. Furthermore, the sections from which a house4 of this sort is built are usually of such a design that standard interchangeable parts may not be used and the sections must be individually designed and custom built to fit the particular style and'structure of the house desired.

I have devised a novel construction for prefabricated houses which is 'characterized by the use of substantially standard `interchangeable units which may be readily connected together in substantially any desired combination whereby not only one but a large number of houses of different sizes and having different floor plans may be built from the same standard units. The units, moreover, are so connected vtogether in the construction of the house as to be readily detachable therefrom when it is desired to enlarge or otherwise alter the oor plan of the house. This detachability of the units further permits the disassembly of a complete house for the purpose of moving the house from one site to another. These units have a further advantage in that a house constructed with a given floor plan may be readily decorated on the exterior and interior to obtain a house having substantially any desired architectural characteristics.

I have found that a prefabricated house having these and many other advantages hereinafter enumerated may advantageously be built up from substantially standardized units which comprise a rigid frame suitably covered on one or both sides to form a unitary panel. More particularly, these units comprise, in general, a wooden structure consisting of substantially parallel stud members and cross members covered with a suitable plywood which, in turn, is rxnly and perlby applying a layer of thermoplastic adhesive material between the surface of the framework and the plywood covering, clamping the covering to the framework, and subsequently subjecting the unit to a hot press whereby the thermoplastic material is melted and the covering material is securely bonded to the framework. The covering material may comprise with advantage that type of plywood Awhich is built up of a plurality of relatively thin layers of a suitable hard wood bonded together with a thermoplastic adhesive material. The resulting product is a panel unit characterized by its light weight and superior strength, extraordinary strength being imparted to the unit in accordance with the well known stressed covering principle.

The parallel stud members extending through the interior of each panel project with advantage a substantial distance at both ends of the panel beyond the plywood covering thereof.I The projecting ends of the studs permit the connection of these ends to the projecting studs of other panels which are to be attached to the end of the first-mentioned panels. Thus, the projecting studs of a side-wall panel may be readily connected to the projecting studs of a ceiling or floor panel. Furthermore, the studs extending along both sides of each panel and projecting beyond both ends of the plywood covering of the panel permit the bolting together of the ends of adjacent side studs of two panels which are thereby connected side by side. The studs serve as studs in the strict sense of the wordwhen the panels are used for the side walls and partitions of outer face of each side stud. Thus, when adjacent panels are bolted together the two projecting edges of the covering material of each panel abut one another and are firmly held together when the adjacent side studs are drawn together by the connecting bolts or the like.

An additional novel feature of this building construction of my invention lies in the means whereby adjacent panels are brought into alignment with one another. Thesev means comprise a spline groove extending substantially the entire length of the outer face of each side stud, the side walls of the spline groove being provided with a bevel. 'Ihese grooves may be accurately cut in the side studs after each panel has been constructed. A suitable spline is provided for fitting into adjacent spline grooves in the adjacent side studs of the panels. The splines are beveled so as to fit partway into the beveled spline grooves but the angle included by the beveled sides of the spline is substantially greater than the angle included by the beveled side walls of the spline groove. By thus providing the spline groove and spline with different angles of bevel, the spine acts as a wedge which may be forced into the spline groove. Accordingly, when adjacent panels are to be connected together a spline is placed between the adjacent side studs with the beveled portion of the spline extending Within the spline groove. As the adjacent side studs are drawn together by the bolting or clamping means at the ends of the side studs, the spline is forced into the spline grooves of the adjacent side studs until the projecting edges of the panel covering material are brought into rm contact. Thus, not only is a substantially air-tight and weather-proof joint maintained at the abutting edges of the panel covering material, but a weather-proof seal is provided by the wedging effect of the splines in the spline grooves of adjacent side studs. 'Ihis method of joining the adjacent panels provides, in addition to the weatherprooiing effect, a highly effectual means for aligning the adjacent panels. Any slight warping of the panel members may be corrected by applying a slight amount of pressure to the convex surface of the warped panel as the bolting means adjacent the ends of the side studs are tightened. In this way an even surface may be insured on the exterior and interior of adjacent panels.

I have found that by providing the abutting edges of the panel covering material with a rounded edge there appears between adjacent panels a V-shaped groove having rounded sides in place of the aesthetically objectionable crack which normally would appear at this joint. The rounded V-shaped groove gives the appearance of a panel design which is not only pleasing in appearance but, together with the connecting means between adjacent panels, further eliminates the necessity of providing these cracks with battens, or the like, as heretofore required in prefabricated houses.

The hollow construction of these panels permits the encasing therein of electric wiring,V

plumbing and heating conduits, and the like, and may be readily packed with an insulating material such, for example, as rock wool.

The exterior of these panels when used as the side walls of a house may be decorated to present substantially any desired architectural design. For example, the panels may be left plain on their exterior, or shingles, clapboards, stucco or the like, may be applied to the wooden surface of the panels. The interior surface of the panels may be left in the natural finish of the plywood and simply stained or waxed, or this surface may be painted or covered with wallpaper if this treatment is desired.y

Furthermore, after a house has been built with these panel units and it is desired for one reason or another to enlarge or alter the floor plan of the house or to move the house from one site to another, those panels which must be removed may be readily disconnected by removing the bolts which hold them adjacent other panelsinthe house construction, and additional panels may be attached to the original structure to build on the desired addition to the original structure. In such cases, it will of course be necessary to make suitable alterations of the foundation of the building.

The panel units, though standardized as to shape and size, may be provided with windows of any desired shape and may be provided with a doorway. Inasmuch as any two panels may be connected to one another, it will be apparent that substantially any desired arrangement of doors and windows may be provided in a house having any given iioor plan. By virtue of this flexibility of design and adaptability to being treated so as to present various types of architectural treatment, a large number of homes having the same floor plan may ber erected side by side with each house having an entirely different and distinctive appearance.

The novel building construction of my invention will be more fully understood by a consideration of the accompanying drawings in which- Figure 1 is a broken face-view of a side-wall panel showing details of its reinforcing structure and is also provided with a cutaway portion to show the interior of the panel;

Figure 2 is a broken side view of a panel showing the spline groove and other features of the panel;

Figure 3 is a broken cross-sectional view of a panel showing details of the spline groove and spline when adjacent panels are connected to one another;

Figure 4 shows means for connecting the projecting ends of adjacent side-stud members of two panels which are connected to one another;

Figure 5 is a broken cross-sectional view of the assembled house showing details of assembly;

Figure 6 is a partial view taken along line 6-6 in Figure 5 with the baseboard removed from the side wall to show details of the connection of the wall panels with the floor panels;

Figure 7 is a similar view taken along line 6-6 in Figure 5 showing details of the connection of an intermediate stud in a wall panel with an intermediate stud in a floor panel;

Figure 8 is also taken along line 6-6 in Figure 5 and shows details of the connection of side-Wall panels at a corner of the house; and

Figure 9 is a perspective view of a floor saddle for connecting a stud in a wall panel with a stud in a oor panel.

The side-wall panel shown in Figure 1, which is of substantially the same structural design as the door and bearing-partition panels shown in Figure 5, comprises a covering material I0, such fory example, as plywood suitably bonded to the side 'studs Il and intermediatestuds I2. The covering material does not extend to the ends .of the studs, thus leaving the projecting ends of studs II and I2 uncovered. 'I'he studs II and I2 are heldjin position while the covering material is applied thereto and the covering material reinforced by means of cross pieces I3. The cross .pieces I3 also serve as fire stops in the building construction.

The cross pieces Il are advantageously provided with holes communicating between the adjacent compartments within a single panel. These holes, or breathers, permit a limited passage of air from one compartment to another thus eliminating the difliculties heretofore encountered where an air space is packed with insulating material without providing means for the escape `of excess moisture which frequently condenses inside of Ythe wall of a house in cold weather. 'I'he condensation of moisture in the insulating material usually destroys the insulating properties of the material, and this condensation of moisture may be prevented by permitting sufficient circulation of air within the panels to carry oil? the moisture. The holes may be located substantially in alignment, as shown inthe drawings, or may be staggered in adjacent cross pieces to insure thorough circulation of air in each compartment. The breathers also serve as a release for the hot gases from within each s ection of the panel when the elements of the panel are being bonded together in a hot press thus permitting expansion and contraction of the panel without bowing or other distortion.

The panel is preferably packed with an insulating material I4, such, for example, as rock wool, before the panel is completely covered, and a metal flashing I5 is advantageously inserted between the studs and the covering material I adjacent the lower portion of the panel before the covering is bonded to the studs. When a sidewall panel is provided with an opening for a Window, a similar metal dashing (not shown) is inserted between the covering material and the top of the window framework of the panel.

The studs II and I2 extend with advantage a further distance beyond the covering material at the lower end of the side-wall panel than they do at the top thereof. The upper and lower projecting ends of side-studs II are provided with transverse bolt holes I6. The upper projecting ends of studs II and I2 are each provided with a single longitudinal bolt hole I1, while the lower projecting ends of the studs are each provided advantageously with two longitudinal bolt holes I8. These bolt holes may be made advantageously somewhat larger than the bolts which are to be used so as to allow for shrinkage or expansion of the structural members of the building construction.

vEach of the side studs, as shown in Figures 2 and 3, are provided with a spline groove 20 extending with advantage the entire length of the side stud, the spline groove being provided with beveled sides as shown in Figure 3. A spline 2i is provided for insertion between the opposing spline grooves of adjacent side studs II of adjacent panels. 'I'he spline may be of wood, metal, or other suitable material, and extends with advantage somewhat less than the distance between transverse holes I8 ineach oi' the side studs II. 'I'he spline is provided withv beveled edges having an angle of bevel substantially greater than that of the side-walls of 'the spline groove 20. Thus, when the spline is forcibly inserted in the spline grooves it becomes wedged therein.

The covering material III preferably extends a short distance, for example, about one-sixteenth of an inch, beyond theface of the side studs II as shown at 22, and the outer edge of the covering material on both sides of the panel is rounded as shown at 23. Thus, when adjacent side-wall panels are attached to one another the projecting edges of the covering material are brought into contact and there is formed a V-shaped groove on the surface of the covering material at the junction between the adjacent panels as shown at 24.

In connecting adjacent side-wall panels, for example, a spline 2| is inserted' between the opposing spline grooves 20 of adjacent side studs II. Bolts are inserted through the transverse holes I6 in the upper and lower projecting ends of the adjacent side studs, and these bolts are then tightened until the projecting edges of the covering material of the adjacent panels are brought into firm contact. The spline being made with advantage of such a size that it can not readily be inserted the full distance into the spline groove, the spline is forcibly wedged into the spline groove as the bolts are drawn up at each end of the side studs. Thus, the close contact between the projecting edges of the covering material is further supplemented by the spline wedged into the spline grooves so that a completely weather-proof joint is provided between the adjacent panels. Furthermore, the spline holds the adjacent panels firmly in alignment. 'I'he covering material which is rxnly bonded to the side studs acts, according to the stressed covering principle, to reinforce the side studs so that by drawing together the ends of adjoining side studs the pressure applied to these ends is applied substantially equally along the entire length of the side studs.

The floor panels shown in Figure 'are built up in substantially the same manner as the sidewall panels A. The upper side of the oor panel which is to be used for the interior may, however, be provided with a heavier or thicker covering to insure a more solid and unyielding floor for the house. The bearing partitiony panels B are substantially identical with the side-Wall panels with the exception that they are slightly shorter than the side-wall panels as shown in Figure 5. The ceiling, roof, and gable members, on the other hand, are preferably covered on only one side of the stud members comprising the joists and rafters thereof, thus facilitating assembly of these panels. The strength and rigidity of the ceiling and roof panels may be increased by bonding to the joists and rafters a strip of covering material I 9 somewhat wider than the joists and rafters. The desired insulating material may be deposited in the ceiling panels either after the ceiling panels have been fastened in position or placed in the panels before assembly and held in position by a suitable material such as Waterproof paper 56 fastened to the joists and cross pieces of the panels as shown in Figure 5. The non-bearing partitions are similar in construction to the side-Wall and bearing partitions although a lighter construction may be used. However, the covering ma.- terial of the non-'bearing partitions of the house extends with advantage the full length of the studs, and these non-bearing partitions may be readily nailed in place without being bolted to the other panels in the building construction. The gable panels are preferably of such design that each panel covers one-half of the open end of the roof construction, and the covering material of the gable panels extends with advantage beyond the reinforcing studs thereof so that this projecting edge of the covering material will cover the exposed upper projecting studs of the sidewall panels.

The assembly of various elements in the house construction is shown in Figure 5. A concrete or other suitable foundation 25 is built to support the side-walls and bearing partition. A wooden sill plate 26, suitably mitered at corners as shown in Figure 8, is fastened to the foundation by means of bolts 29 set in the foundation and extending upwardly through the sill plate. A floor panel is then laid across the sill plates on the side-wall and bearing partition foundations, and each of the projecting intermediate joists of the floor panel is then bolted to the sill plate by means of a stamped metal floor stirrup 21, such -as that shown in Figure 9, through holes 30 provided in the stirrup. A side-wall panel is then placed on end with the lower end of the projecting studs resting upon the sill plate. The metal floor stirrups 2'I are then fastened to the lower end of each projecting intermediate stud by means of bolts extending through the longitudinal holes I8 with one projecting edge 28 of the stirrup positioned under the lower end of stud I2. The assembled side-wall and floor panels are held in position on the sill plate by means of a screw or lag bolt embedded in the sill plate through a hole provided in projecting edge 3| of the floor stirrup A plan view of the connection between intermediate studs I2 of the sidewall panel and the corresponding projecting joists of the floor panel is shown in Figure 7.

After adjacent side-wall panels have been erected and bolted together (as described above and as shown in Figure 6) and a separate floor stirrup has been attached to each of the adjacent sidestuds II, the adjacent side joists of adjacent floor panels are drawn together by means of bolts 32 extending through holes 30 in their respective stirrups, a spline having been positioned between the opposing spline grooves in these side joists of the floor panels. These splines, besides insuring a weatherproof joint between the floor panels, also prevents movement of adjacent panels when subjected to the strain of a person walking along the floor.

The adjacent ends of the floor panel joists which abut end to end are connected together by bolts 33 extending through holes in an L-shaped metal saddle 34. O-ne leg of the L-shaped floor saddle rests upon the top of the abutting ends of these joists and has welded upon the upper face of this leg a channel shaped member 35 adapted to engage the lower end of the projecting studs of a bearing partition panel. Similar stirrup and saddle members are provided for connecting the side-wall panels and bearing partition panels to the ceiling panels. The ceiling stirrup 36 is similar to the floor stirrup with the exception that the projecting portion 28 of the ceiling stirrup is provided with an additional projection '3`I extending upwardly and at rightangles to projection 28. Projection 31 of the ceiling stirrup is adapted to engage the ends of the rafters 38 of the roof panel. The roof panels are supported and held ln position by a suitable roof strut 39 appropriately connected to the ceiling saddle 40, and these roof panels are applied after the side-walls, partitions, and ceilings have been assembled. As mentioned above, the ceiling saddle is similar in construction to the oor saddle 34. Roof braces 4I are further provided for supporting the mid-point of each of the rafters of the roof panels, and the mid-point of each of the joists of the ceiling panel may be supported from the roof panels by means of metal hangers 42, as shown in Figure 5. Roof strut 39, brace 4I, and hanger 42 may be so constructed, as shown in Figure 5, as to be folded for shipment yet readily opened into proper position for supporting the roof and ceiling panels. The gable panels may then be placed in position and bolted to the rafters of lthe roof and the upper projecting side-wall struts so as to cover the open ends of the roofing and the uncovered upper projecting studs of the end-wall panels.

The end-wall and side-wall panels are connected at the corner by means of an angle iron 43 lag-bolted to the adjacent side studs of the panels at intervals longitudinally along these studs. The lower ends of the projecting studs of the end-wall panels are firmly attached to a side joist of the floor panel by lag screws, or the like, inserted through holes I8 when the projecting studs of the end-wall panels are all adjacent the same side joist of a floor panel (as shown in the upper portion of Figure 8).

After the panels have been securely fastened together the open spaces where the panels are connected together are appropriately covered. A

curtain board 44 is inserted under the flashing I5 and nailed or otherwise attached to the lower projecting ends of studs II and I2. A similar gutter board 45 is used to cover the upper projecting ends of studs II and I2, and a gutter 46 may be fastened to this gutter board. A molding 4'I is attached to the lower edge of the covering material on the side-wall panels to cover the flashing I5, andsuitable flashing 48 is provided to seal the joint between the overhanging end of the roof panel and the gutter 46. A suitable hashing 5I may then be secured over the ridge at the peak of the roof. Windows and doors are also mounted in the openings provided in the sidewall panels to complete the enclosure of the house.

Within the interior of the house, ceiling molds 52 enclose the space between the covering material of the ceiling, side-wall and bearing partition panels. Base-boards 53 are provided adjacent the lower portion of the interior walls of the rooms and a complete covering is furtherfpof' vided by base-board shoes 54. Spacers 49 attached to the studs II and I2 of the side-wall panels are substantially the same thickness as the plywood covering and serve to hold the lower portion of the base-boards 53 in the proper vertical position. 'I'he corners of the side-walls are covered on the exterior of the house by means of ornamental corner pieces 55 which may be nailed to the outside of the side-wall panels. Suitable vertical corner molds, similar to ceiling molds 52, may be used to seal the corners of the interior'of the house. Thus, there is provided a completely nished exterior and interior for all connections between adjacent panels in the building construction. All necessary electric Wiring if desired may be inserted in the junctions between adjacent vertical and horizontal panels before the nishing material is applied to cover these junctions.

It will be seen, therefore, that the novel insulated panel construction of my invention may be used in building prefabricated houses suitable for permanent residential purposes and of such' design and construction that weatherproof houses of various sizes 4and a plurality of door plans may be readily constructed from these standard interchangeable panels. Inasmuch as 'the panels are covered with plywood, houses built up of these panels are readily adapted to various external and internal decorations either at the time of construction or subsequent thereto. My novel method of bolting these substantially standardized panels together provides forming a weather-tight joint between adjacent panels in such a manner as to permit their disassembly. f Houses constructed with these panels are preeminently adapted to subsequent rearrangement or enlargement of their floor plans by using the same standard panels as well as to the complete disassembly and reconstruction of the houses in a diilerent location. The fact that the standard side-wall panels may be provided with various sized windows or doorways and the fact that any two side-wall panels may be connected to one another permit the erection side by side of a large number of homes having the same floor plan with each home having an entirely different and distinctive appearance.

1. In building construction, the improvement l which comprises a plurality of panels suitable for eled groove extending substantially the entire the side studs.

2. In building construction, the improvement which comprises a plurality of panelssuitable for use as sections of walls, partitions, oors, and ceilings of a prefabricated house, each of the panels comprising substantially parallel side studs and intermediate studs held in spaced relationship by substantially inflexible covering material bonded to both sides of the parallel studs, a bevlength of the outer face of each stud and opening outwardly therefrom, and a beveled spline positioned between opposing grooves in the side studs of adjacent panels, the angle of bevel of the spline being substantially greater than the angle of bevel of the grooves in the side studs.

3. In building construction, the improvement 'which comprises a plurality of panels suitable for use as sections of walls, partitions, floors, and ceilings of a prefabricated house. each of the panels comprising substantially parallel side studs and intermediate studs held in spaced relationship by substantially inflexible covering material bonded to both sides of the-parallel studs, the covering material terminating a substantial distance from both ends of the parallel studs, a beveled groove extending substantially the entire length of the outer face of each side stud and opening outwardly therefrom abeveled spline p0- sitioned between opposing grooves of the side studs of adjacent panels, the angle of bevel of the spline being diierent than the angle of bevel of the grooves in the side studs, and bolting means adjacent the uncovered ends of the adjacent side studs.

fi. In building construction, the improvement which comprises a plurality of panels suitable for use as sections of walls, partitions, floors, and ceilings of a prefabricated house, each of the panels comprising substantially parallel side studs and intermediate studs held in spaced relationship by substantially inflexible covering material bonded to both sides of the parallel studs with insulating material positioned within the panel, a beveled groove extending substantially the entire length of the outer face of each side stud and opening outwardly therefrom, and a beveled spline positioned between opposing grooves in adjacent panels, the angle of bevel of the spline being different than the angle of bevel of the grooves in the side studs.

5. In building construction, the improvement which comprises a plurality of panels suitable for use as sections of walls, partitions, floors, ceilings and roof of a prefabricated house, each of the panels comprising susbtantially parallel side studs and intermediate studsheld in the spaced relationship by substantially inflexible covering material bonded to at least one side of the parallel studs, the covering material terminating a substantial distance from both ends of the parallel studs, a beveled groove extending substantially the entire length o f the outer side face of each side stud and opening outwardly therefrom, and a beveled spline positioned between opposing grooves of the side studs of adjacent panels, the angle of bevel ofthe spline being diierent than the angle of bevel of the grooves in the side studs.

6. A prefabricated building the walls, partitions, iloors, ceilings, and roof of which are made up of a plurality of panels comprising substantially parallel side studs and intermediate studs held in spaced relationship by substantially inflexible covering material bonded to at least one side of the parallel studs With a beveled groove opening outwardly from and extending substantially the entire length ofthe outer side face of each side stud and with a beveled spline positioned between opposing grooves in adjacent panels, the angle of bevel of the spline being different than the angle of bevel of the grooves in the sidestuds. 1

7. In building construction, the improvement which comprisesa plurality of panels suitable for use as sections of walls, partitions, floors, ceilings and roof of a prefabricated house, each of the panels comprising substantially parallel side studs and intermediate studs held in spaced relationship by substantially inflexible covering material bonded to at least one side of the parallel studs and projecting a relatively short distance beyond the side studs, the projecting edges of the covering material being partially rounded, a beveled groove extending substantially the entire length of the outer face of each side stud and opening outwardly therefrom, and a beveled spline positioned between opposing grooves in adjacent panels, the vangle of bevel oi' the spline beingsubstantially greater than the angle of bevel of the grooves in the side studs.

FOSTER GUNNISON. 

